Main
SVM178-B
April, 2011
11415,11416,11468
VANTAGE500
i i
FOR ENGINE powered equipment.
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii ii
FUMES AND GASES can be dangerous.
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
iii iii
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
WELDING and CUTTING SPARKS can cause fire or explosion.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
VANTAGE 500
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
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Electromagnetic Compatibility (EMC)
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Installation - VANTAGE 500 Deutz F3L912 (Code 10995)
TECHNICAL SPECIFICATIONS - Vantage 500 DEUTZ (K2271-1)
RATED OUTPUT @ 104F(40C) - WELDER
OUTPUT @ 104F(40C) - WELDER AND GENERATOR
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Figure A1.1 Connection of the Vantage 500 to Premises Wiring
Operation - VANTAGE 500 Deutz F3L912 (Code 10995)
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WELDING CONTROLS
AUXILIARY POWER CONTROLS
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WELDER OPERATION
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B1.11 B1.11
TABLE B1.4 VANTAGE 500 EXTENSION CORD LENGTH RECOMMENDATIONS
outputs as long as it is of ample size. Table B1.4 lists
TABLE B1.3 Vantage 500 Duetz Simultaneous Welding and Power Loads
(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%
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Accessories - VANTAGE 500 Deutz F3L912 (Code 10995)
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Maintenance - VANTAGE 500 Deutz F3L912 (Code 10995)
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AIR FILTER
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COOLING SYSTEM
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BATTERY MAINTENANCE
WELDER/GENERATOR MAINTENANCE
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Installation - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)
TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-1)
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Figure A2.1 Connection of the Vantage to Premises Wiring
Operation - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)
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B2.11 B2.11
TABLE B2.4 VANTAGE 500 EXTENSION CORD LENGTH RECOMMENDATIONS
TABLE B2.3 Vantage 500 Duetz Simultaneous Welding and Power Loads
(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%
* Each duplex receptacle is limited to 20 amps.
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Accessories - VANTAGE 500 Deutz F4L2011 (Codes 11180, 11415)
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Maintenance - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)
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FUEL FILTERS
Latch
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Installation - VANTAGE 500 Deutz D2011L4i (Code11468)
TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-2)
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Figure A3.1 Connection of the Vantage to Premises Wiring
Operation - VANTAGE 500 Deutz D2011L4i (Code 11468)
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B3.11 B3.11
TABLE B3.4 VANTAGE 500 EXTENSION CORD LENGTH RECOMMENDATIONS
TABLE B3.3 Vantage 500 Duetz Simultaneous Welding and Power Loads
(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%
* Each duplex receptacle is limited to 20 amps.
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Accessories - VANTAGE 500 Deutz F4L2011 (Codes 11180, 11415)
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Maintenance - VANTAGE 500 Deutz D2011L4i (Codes 11468)
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FUEL FILTERS
Latch
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COOLING SYSTEM
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Installation - VANTAGE 500 Cummins B3.3 (Code 10996)
TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1)
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Figure A4.1 Connection of the Vantage to Premises Wiring
Operation - VANTAGE 500 Cummins B3.3 (Code 10996)
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION.
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B4.11 B4.11
TABLE B3.4 VANTAGE 500 EXTENSION CORD LENGTH RECOMMENDATIONS
TABLE B3.3 Vantage 500 Duetz Simultaneous Welding and Power Loads
(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%
* Each duplex receptacle is limited to 20 amps.
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Accessories - VANTAGE 500 Cummins B3.3 (Code 10996)
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Maintenance - VANTAGE 500 Cummins B3.3 (Code 10996)
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COOLINGSYSTEM
Strainer
Shut-Off Oil Filter Fuel Filter/ Water Separator
Oil Fill Cap
Dip Stick
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AIR FILTER
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Installation - VANTAGE 500 Cummins B3.3 (Code 11181, 11416)
TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1)
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Figure A5.1 Connection of the Vantage to Premises Wiring
Operation - VANTAGE 500 Cummins B3.3 (Codes 11181 & 11416)
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION.
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AUXILIARY POWER OPERATION
SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS
PLUS OR OR
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Accessories - VANTAGE 500 Cummins B3.3 (Codes 11181 &11416)
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MAINTENANCE - VANTAGE 500 CUMMINS (CODE 11181 & 11416)
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COOLINGSYSTEM
Strainer
Shut-Off Oil Filter Fuel Filter/ Water Separator
Oil Fill Cap
Dip Stick
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TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1 E-1
120VAC
ON
THREE-PHASE
BATTERY, ENGINE, ROTOR, STATOR, PULL COIL BOARD AND PERIPHERAL BOARD ENGINE PROTECTION
WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK
E-4 E-4
FIGURE E.4 - POWER MODULES AND WELD CONTROL BOARD
120VAC
HOLD
WELD CONTROL BOARD
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion
ENGINE ROTOR STATOR
WIN DI G
MECHANICAL ROTATION ALTERNATOR
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
PULSE WIDTH MODULATION
CHOPPER TECHNOLOGY FUNDAMENTALS
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TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
PC BOARD TROUBLESHOOTING PROCEDURES
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CASE COVER REMOVAL AND REPLACEMENT PROCEDURE
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE
POWER RESISTOR
INSULATED GLOVE
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
CHOPPER MODULE RESISTANCE TEST PROCEDURE
B1 B4 B5 B6
B2 B3
CHOPPER MODULE RESISTANCE TEST (CONTINUED)
CHOPPER TEST CHOPPER TERMINAL CONNECTIONS
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IDLER SOLENOID TEST PROCEDURE (CUMMINS ENGINE ONLY)
IDLER SOLENOID TEST PROCEDURE (CONTINUED)
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SHUTDOWN SOLENOID TEST PROCEDURE
ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CUMMINS ENGINE ONLY)
MARK BLOWER PADDLE HERE
Shutdown Solenoid
LEFT SIDE
Idler Solenoid
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY) HIGH IDLE NO LOAD
15.8 ms
0 volts
50V 5ms
ROTOR RESISTANCE TEST
SLIP RINGS
BRUSH HOLDER ASSEMBLY
ACCESS PANEL
ROTOR RESISTANCE TEST (CONTINUED)
FLASHING AND ROTOR VOLTAGE TEST
#200A #200B #201
FLASHING AND ROTOR VOLTAGE TEST(CONTINUED)
STATOR VOLTAGE TEST
AUXILIARY POWER AND WELD WIND- INGS TEST
STATOR LEADS
Back of Control Panel Typical 3 Auxiliary Machine
FIGURE F.11 AUXILIARY LEAD TEST LOCATIONS ON BACKOFCONTROLPANEL
F-35 F-35
Back of Control Panel Typical 1 Auxiliary Machine
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OUTPUT RECTIFIER BRIDGE TEST
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DIODE TEST RECTIFIER TERMINAL CONNECTIONS
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ELECTRONIC GOVERNOR TEST
ELECTRONIC GOVERNOR TEST (CONTINUED)
CHARGING CIRCUIT TEST
#239 #281
#238
CHARGING CIRCUIT TEST (CONTINUED)
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)
HIGH IDLE NO LOAD
15.8 ms
0 volts
50V 5ms
0 volts
50V 5ms
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)
MAX TAP MAX CONTROL POT HIGH IDLE NO LOAD
0 volts
20V 0.1ms
NORMAL WELD VOLTAGE WAVEFORM (STICKCC)
MACHINE LOADED TO 500 AMPS AT 40 VOLTS
0 volts
10V 5 s
NORMAL TIG MODE VOLTAGE WAVEFORM
LOADED TO 200A 16 VOLTS
0 volts
50V 5MS
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV) HIGHIDLE - NOLOAD
0 volts
20V 0.1ms
NORMAL WELD VOLTAGE WAVEFORM (WIRECV)
MACHINE LOADED TO 500 AMPS AT 40 VOLTS
SHUTDOWNSOLENOID REMOVAL AND REPLACEMENT
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (DEUTZ)
REASSEMBLY
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CUMMINS)
REASSEMBLY
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OUTPUTRECTIFIER REMOVAL AND REPLACEMENT PROCEDURE
OUTPUTRECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued)
STATOR/ROTOR REMOVAL AND REPLACEMENT
PLUG FUEL LINES
{
U-BOLTS (2)
LEADS #229 AND #242D
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CONTROL BOX PULL COIL PC BOARD (LEADS #265 & #227
12 VDC STUD LEADS #232L & #232M
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FLEX PLATE
ROTOR
BLOWER SEGMENT (4)
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RETEST AFTER REPAIR
ENGINE RPM
WELDER DC (STICK) OUTPUT
WELDER CV (WIRE) OUTPUT
RETEST AFTER REPAIR (CONTINUED)
TOUCH START TIG MODE OUTPUT
AUXILIARY POWER OUTPUT
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TABLE OF CONTENTS - DIAGRAM SECTION
* NOTE:
ELEcTricaL DiaGramS
WiriNG DiaGram - vaNTaGE500 - G4342 (cODE 11095 DEuTz)
+-
-
+
ELEcTricaL DiaGramS
WiriNG DiaGram - vaNTaGE 500 - G4329 (cODE 10996)
-
+
-
ELEcTricaL DiaGramS
WiriNG DiaGram - vaNTaGE 500 - G4847 (cODES 11180,11415 & 11468)
-
+
-
ELEcTricaL DiaGramS
WiriNG DiaGram - vaNTaGE 500 - G4971 (cODES 11181 &11416)
+
-
+
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) paGE 1
of control
lower rear of fan b
citor and
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) paGE 2
NOTALL CIRCUI TS ARE USED ALL THE TI ME.
J7OUTPUTCONTROL,ARC FORCE,MODESELECT
(
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) paGE1
of control
lower rear of fan b
citor and
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) paGE 2
NOTALL CIRCUI TS ARE USED ALL THE TI ME.
J7OUTPUTCONTROL,ARC FORCE,MODESELECT
(
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4848 (cODES 11180, 11415 & 11468 DEuTz) paGE 1
of engine
ht front
Solenoids located on rig
ELEcTricaL DiaGramS
SchEmaTic - cOmpLETE machiNE - G4848 (cODES 11180, 11415 & 11468 DEuTz) paGE 2
GROUND
H
RT